Uranium processing



Feb. 2, 1965 s. l.. REEsE ETAL 3,168,369

URANIUM PROCESSING Filed Dec. 18, 1961 2 Sheets-Sheet 1 Feb. 2, 1965 s. 1 REEsE ET AL United Stat-es Patent 3,l03,369 Patented. Feb. 2, i965 [ice 3,168,369 URANIUM PRCESSHNG Stanton L. Reese and Thomas C. Runion, both of Erwin, Tenn., assignors to W. R. Grace Qc., New York, NX., a corporation of Connecticut Filed Dec, 1S, 196i, Ser. No. .59574 4 Claims. (Cl. 23-d.5)

This application relates to the processing of uranium and more particularly concerns a dry process for the conversion of the hexafluoride of this metal to the dioxides, trioxides or octo-oxides. The oxides have a high degree of chemical purity and the dioxides have highly desirable physical properties such that when compacted they sinter to extremely high density at elevated temperatures. This invention applies particularly to UFS where the principal uranium isotopes are U-238 and U-235.

Since UFS is the uranium compound used in obtaining any desired U-235zU-238 ratio, it is the most common raw material used to produce various commercially usable uranium compounds and the metal, except where the U-2352U-238 ratio is that found in nature. Uranium trioxide (U03) presently has experimental application. Triuranium octo-oxide (U308) has considerable application in ceramic coloring and in nuclear fuels. Uranium dioxide (U02) is used extensively as a nuclear fuel and principally where it has been compacted and further densitied by treatment at high temperature.

The production of these oxides was heretofore accomplished by the reaction of the hexafluoride with a liquid and the precipitation in a liquid of an uranium compound, which could require such steps as filtering, washing, drying, heating in the required atmosphere to produce the desired oxide, and grinding of the oxide if a tine powder was desired. Due to the peculiar ssioning property of the uranium 235 isotope, which upon iissioning releases considerable quantities of neutrons and other radioactivity, its concentration must be controlled in chemical processing of uranium to prevent a nuclear reaction.

' itis, accordingly, the principal object of the invention to provide a'process which economically converts the hexaiiuoride of uranium` to a fine oxide powder of desired particle diameter without grinding, and to produce a dioxide that, when compacted, will readily density upon exposure to high temperature to-a piece having tine grain,

vgood physical integrity and a density from 90% to 99% of the theoretical density of the dioxide.

Another object of the invention is to provide process conditions such that uranium may be processed and the U-235 content of the apparatus may be increased, Vwhere 'the U-235zU-238 ratio is sutlciently high that a nuclear vreaction is possible, by reducing the hydrogen available i temperature of the apparatus is maintained' above the condensation temperature Q30-350 T11-preferably 300 F.) of steam at the pressures (approximate 1 atmosphere) found in the apparatus, produces a tine, dry powder, uranium oxyiuoride.

The reaction is given by the following chemical equation:

Ure 21120 UOQFZ 4HF Gas Dry steam Solid Gas 111 CXCCSS We have found that the powder, which has many small particles of about 0.10 micron in diameter, can be separated from the hydrogen fluoride gas and the excess steam by gravity, followed by such methods of separation as high velocity cyclone separators, backed by small pore filters. The configuration of the chamber for contacting UF6 and steam can be varied, providing the two gases contact each other somewhere in the system since reaction is instantaneous. In this process two-thirds of the fluoride from the compound UF6 is removed from the uranium as hydrogen fluoride or hydrofluoric acid gas. This gas passes off and may be inexpensively dissolved in a water scrubber, as opposed to neutralizing it with more expensive neutralizing compounds, as is required in a liquid process where all the fiuorine dissolves with the uranium. In the liquid process large volumes of filtrate are encountered from the precipitation of the uranium, and large volumes of wash water are often required to remove the fluorides from the precipitate. These ltrates generally contain suicient uranium to require processing to remove the uranium before they may be discarded. The uranium content of the filtered gases from our process is suficiently low that the scrub solution will contain 0.01 to 0.05 gram per liter uranium and need not be treated for uranium removal.

The UOZFZ powder produced by this process is not freeflowing, but tends to cling together. It does not, however, have a tendency to pack. We have discovered that the powder may be fed into a conventional screw feeder by vibrationfsuch as that obtained with conventional electric or air vibrators and that the material will feed very well through a screw feeder. Upon being delivered from the screw, it is a powder and very similar in appearance to the U02F2 fed into the screw. We have discovered that if the powder is subjected to a temperature of 800 F. to 1000" F. in steam and in the absence of air U03 powder is produc-ed, as given in the following chemical formula:

soo F. U02F2 H2O U03 2HF Powder Steam Powder Gas We have found that at a slightly greater temperature in the presence of air or other oxygen containing gas the resultant product is U308. `We have discovered that the UOZFZ powder, when heated to a temperature 1000 F. to 1800 F. in the presence of hydrogen, reacts according to the following chemical equation:

Gas Powder U02 -i- 2HF Powder i Gas The addition of steam also aids in the dilution and rapid removal of by-product HF. Typically, the resulting U02 produced in our apparatus has 50 ppm. to 131 p.p.m. iiuorine, whereas without the actions of steam described above, uorine often occurs in excess of V1000 ppm. We have found that the UO2F2 may be continuously or semi-continuously reacted to a static bed and that the reaction to om'de also proceeds Very well in a rotating tube calciner or stationary tube with a revolving ribboniiite screw. Although other materials of construction may be satisfactory, we have found nickel alloys to be the most resistant to the corrosive atmosphere.

We have discovered that the average particle size of either U02 or U3O8 product can be controlled within a range of 0.55 and 2.5 microns average particle diameter by controlling the temperature at which the UOZFZ is subjected in its conversion to UBOB or U02 between 1000 F. and 1400 F. In the lower temperature range, the reaction of UO2F2 with steam and air or steam and hydrogen promotes fluoride removal. Both the presence of fluoride and high temperature have a tendency to agglomerate and densify the particles, resulting in both an increase in the average particle diameter and in bulk density. The bulk density varies directly with the particle size in this temperature range and has been observed in the range of 0.65 gm./cc. to 1.5 gms/cc. Above 1400" F. the particle size continues to increase, but the bulk density remains nearly constant; the process of this invention lends itself to the production of a controlled particle size and bulk density as desired within the ranges stated to meet the various requirements for fabrication.

It is known that when the percent of the uranium 235 isotope associated with the U-238 isotope has been increased over that found in nature, i.e., 0.7115 U-235 balance principally U-238, the U-235 may fission under proper conditions of neutron moderation and reflection. The higher the percentage of the U-235 isotope in a given quantity of uranium, the greater the probability of a nuclear reaction. Also, over a wide range the more neutron moderator present the greater the probability of a nuclear reaction. Hydrogen is an excellent neutron moderator and the presence of hydrogen atoms in hydrogenous liquids such as water greatly limits the quantity of U-235 and, in turn, the batch size that may beY safely processed in a given apparatus in a hydrogenous liquid at one time. Safely, as used here, pertains to a nuclear reaction with its resulting radiation, which must be avoided in chemical processing. Table I shows ,the diiference in the U-235 mass that may be permitted TABLE I U235.m1zss safe in liquid H2O vs. U-235 mass safe in steam Liquid (H50) Steam U-235 Any U-Con- 3n0 F. vand Enrichment, centration one atmosperccnt U235 mass, phere) kg. U-235 mass,

lrg.l

1 UOzFz at 0.2 gru/cc.

It is apparent from the description of the process that only steam, hydrogen, which may be disasrsociated ammonia, and air are required as raw materials for this process with water in the oft-gas scrubber. No chemically basic compounds or other agents are required.

It is known Vin the art of compacting and sintering U02 into shapes, that a small average particle size of about one micron diameter and large particle surface area are advantageous to obtaining good densication when the compact is subjected to elevated temperatures. It is also known in the art that U02 produced at low temperatures is much more active and densities more readily than U02 powder which has been produced at or'subjected to high temperatures.

Without particle size Vreduction this powder, when compacted to a density of only 6.3 gms/cc. and when heated to 1600 C. in hydrogen, densiiied Vin excess of 94% of theoretical. When compacted to 6.8 gms/cc. and treated as above, the sintered compacts were in excess of 96% of theoretical. The sintered compacts appeared physically sound and of tine grain. Therefore, by the process of this invention, U02 is produced which has improved densication properties when compacted and subjected to elevated temperatures. n

Our invention is illustrated by the following specific by non-limiting examples.

lEXAMPLE I Applied operation of the process is best shown with reference to FIGURE 1. This drawing shows graphically the production of UOZFZ from UF6.

In this process, 91.4 pounds of UF6 were passed through the system per hour. v Y vaporizer 1 which is heated to 170-250 F. The gaseous UF6 was passed through the line 2 which was heated Vto 300 F. to the reactor 3. Dry steam was fed into Y the reactor through the line 32 at a rate of 18.8 pounds of steam (as H2O) per hour. The off-gases from this operation which consists of hydrogen fluoride and steam Vwere passed into the cycloner separator 4 and through the iilter 5. The eiuent from the filter was a mixture of HF and steam which was passed through a water scrubber to recover the HF solution as a by-product. The product, UOZFZ, Ywas collected in three areas in the bottom of the reactor 3, cyclone separator 4, and the lter unit 5. The product was then passed intora product hopper for use in subsequent steps. Using the feed rates set out above, a production of pounds of UO2F2 per hour was maintained in the continuous'operation. The equipment was operated at pressures of 0 to 3 p.s.i.g, with no eifort being made to increase the pressure above atmospheric.

The reactor was a 111/2 inch internal diameter vertical tube which had a vibrator'attached at the reaction zone,

the reactor was heated to a temperaturerof 300-500 TABLE II Run Number 1 2 i 3 vBottom of Reactor, percent i 35. 9 3B. 40 53.20 First 6" Cyclone, percent 48. 7 34. 3 33. 4 Second 6 Cyclone, percent 8. 1 22.0 11.9 Filters, percent 6. 6 3. 2 1. 2 Scrub Solution, percent 0.7 0. 3

The UF6 was vaporized in theV TABLE 1n ously through the reactor to help cool the product and to insure adequate off-gas removal. This equipment and process makes it possible to produce 70 pounds of U02 Element Typical Mgrgimum per hour. The equipment was operated at a pressure analyss ppm mpumeSP-P'm' 5 of 0 to 5 p.s.i.g. with a residence time of 2 hours in the A reactor. The reactor was 111/2 inches in diameter and Alg: 21- gjl' 211/2 feet long. The reactor was equipped With a Varilsl b ID 10 able speed nickel alloy ribbon flight screw with one 'B 2g 01(2)'8. end free. The product Was removed from the product Ba. ND 5 ND 5 10 cooling hooper and packaged in the U02 product pack- Be- ND 5 ND 5 U d d B1" 1 ND 1 aging, o. 1s use to prepare compacts as escribed 1n 8g f1 1 1 0 3 Example III. The eiect of temperature variation from @L q 3: 1000 to 1400 F. in the preparation of U02 is shown C11 8a 100. in Table IV. The product obtained at 1000 F. was Fei0 10. Ge ND 1 ND 1 15 less dense than the materials prepared at higher tem- Hg ND 10 ND 1O peratures but had essentially the same porosity charm ND an D V Mg" gl 50 acteristics of tne materlal prepared at 1200 F., and 1n fol 9 1 1 1 general was a good product. The data indicates that a ND 7L, Njj 75 satisfactory product for dcnsication by sintering can be 11211 @gm 1 3 20 obtained at operation from 1000-1400 E. Preferred PB: 1 3 conditions would be 1200-1400 F. Sb.- ND 1 ND 1 i s 3. EXAMPLE III [1 ST ND mn ND 100 The uranium dioxide (U02) prepared from the Vprocess Te. ND 1 ND 1. TL ND mn ND 100 25 described 1n Example II can be formed into smtered $1" ggg() g compacts using the equipment shown diagrammatically Zi 37 2. in FIGURE 3. The process is as follows: U02'Was fed gqggzvinto the product mixing zone Where it Was mixed 'Lfmatzsmr 0.47%: with an organic binder and Water. This wet mix was passed to the granulator 21 Where it was ground Wet to reduce the size of the particles. The Wet granules Physiixcai Charactterstis: t 02 were fed to the dryer 22 where the water was removed r 1 Bgffiacns'ltglenfef 0.2 and then t0 a mixer 23 Where they were prepared for Porosity compacting by the addition of a die lubricant. The

TABLE IV Test Temp., Particle Bulk Tap Perppm. No. F. Color Porosity Size Density, Density, cent F- O/U gJce. g./cc. ,L

1 1000 Light brown, orange .80 Est. .58;i .84 1.28 87.87 558 2.053

and grey particles. 2 1200 Medium brown .8O 1.0 1.2 1.7 88.00 105 2. 028 3 1400 Medium brown .79 2.2 1.41 2.13 88. 05 65 2.019

orange particles. 4 1600 Dark brown, orange .794 1.681.; 1.32 1.93 88.08 47 2.013

and White particles. 5 1400 Medium brown .so .68 1.6 88.06 61 2. 018

EXAMPLE II A typical utilization of the UQZFZ produced in the process described in Example I is illustrated in FIG- URE 2. This diagram shows the plant process for the preparation of U02 from the U02F2 product. In this reactor UOZFZ was fed into the continuous calciner 10 at a rate of 80 pounds of UOZFZ per hour. Hydrogen was fed into the reactor into the line 12 at a rate of 0.8 pound per hour and steam Was ted at a rate of 9.36 pounds per hour, through the line 13. The reactor was heated to a temperature of 1200-1300 F. The off-gas from the reactor which contains steam, hydrogen, and HF was removed through the cti-gas line 114 through the HF scrubber 15 and the hydrogen was removed from the oit-gas by burning it in the hydrogen burner 16 before venting it to the stack. The product from the calciner was passed through a line 1S to the cooling hopper 17, a nitrogen purge from line 19 was fed continumixed product was fed to the compacting press 24 and the green compacts were fed into an oven Z5 Where the binder Was removed by the combination of heat and the sweep of an inert gas. The compacts were then transferred to the high temperature furnace 26 where they were heated in the presence of hydrogen. The sintered compacts were removed from this furnace and were then ready for machining or packing. Using this process, it is possible to prepare a uranium dioxide which has the chemical properties set out in Table V. When compacted to a density of 6.3 grams per cc. and heated to 1600 C. in the furnace described above, the resulting density is in excess ofy 94% of theoretical. When compacted to 6.8 grams per cc. and treated as above, the

' compacts are in excess of 96% theoretical density. Therefore, by the processes of this invention, U02 is produced which has improved densication properties when compacted and subjected to elevated temperatures.

'Z7 TABLE V Chemical:

Percent U-87.92 Fluorine--70 ppm. O/ U Ratio-2.04

Spectrochemical Concentration (p.p.m.)

Physical:

Bulk Density .654 gms/cc. Tap Dens1ty iognis/ec. Porosity Particle (average) .55 microns.

U02 has beenrproduced by the process of this invention with chemical properties very similar to those given in Table V above and physical properties as follows:

Bulk density .80 gms/cc. Tap Density 1.52 gms/cc. Porosity .770.

Average particle size 1.04 microns.

Obviously, many modifications and variations of the invention, as herein and above set forth, may be made without departing from the essence and scope thereof, and only such limitations should be applied, as indicated in the appended claims.

What is claimed is: n

1. A process for the preparation of uranium trioxide which comprises converting gaseous uranium hexauoride to uranyl uoride by treating'the hexaiiuoride with steam pressure followed by conversion of the uranyl fluoride to uranyl oxide by treatment of the uoride at a temperature about 800 to 1000 F. in the presence of steam While carefully excluding air from the reactor and recovering the uranium trioXid-e product. Y

2. process for the preparation oi' triuraniunl octoxide which comprises converting gaseous uranium hexailuoride to uranyl uoride by'treatment of the hexailuoride with steam at a temperature of about 230 to 350 F. at atrn spheric pressure followed byfconversion'of the uranyl fluoride to the octoxide by treatment of the Vuranyl uoride at a temperature of about 1000fto1800 F. With steam and air and recovering the octoxide product.

3. A process for preparing uranium dioxide Withan average particle diameter of 0.55 to f2.5 microns and a bull: density of 0.65 to 1.5 grams per cc. which comprises treating gaseous uranium hexaiiuoride withA steam at a temperature of 2230-550.DVV F., followed by treatment of the uranyl fluoride With hydrogen at a temperature of 1000 to 1400 F. for a period of about 2 hours and recovering the uranium dioxide product.

4. A process for preparing uranium dioxide with an average particle size of 0.55 toV 2.5 microns and a bulk 'density of 0.65 to 1.5 wherein the uranium dioxide product contains no more than about to 131V p.p.1n. of iiuorine which comprises vaporizing UF6 by heating to a temperature of about -250 F., passing the hex'aiiuo-V UNITED STATES PATENTS 9/59 GooginV 23-145 8/62 Schwartz 23-145 OTHER REFERENCES Katz et al.: The Chemistry of Uranium, 1st Ed. (1951), pp. 319-321, 570-572. lWCG'aW-Hill BOOk CO.,

K NYC. Y

at a temperature of about 230 to 350 F. at atmospheric AEC Documents: ANL-6023, pp. 3-7, 10-14, August 1959; ANL 6145, pp. 124-128, Chem. Eng. Division. Summary Report for anuary-March 1960; ANL61S3, pp. 118-122, Chem. Eng. Division; Siunrnary Report for April-June 1960.

CARL D. QUARFORTH, Primary Examiner. 

1. A PROCESS FOR THE PREPARATION OF URANIUM TRIOXIDE WHICH COMPRISES CONVERTING GASEOUS URANIUM HEXAFLUORIDE TO URANYL FLUORIDE BY TREATING THE HEXAFLUORIDE WITH STEAM AT A TEMPERATURE OF ABOUT 230* TO 350*F. AT ATMOSPHERIC PRESSURE FOLLOWED BY CONVERSION OF THE URANYL FLUORIDE TO URANYL OXIDE BY TREATMENT OF THE FLUORIDE AT A TEMPERATURE ABOUT 800* TO 1000*F. IN THE PRESENCE OF STEAM WHILE CAREFULLY EXCLUDING AIR FROM THE REACTOR AND RECOVERING THE URANIUM TRIOXIDE PRODUCT.
 3. A PROCESS FOR PREPARING URANIUM DIOXIDE WITH AN AVERAGE PARTICLE DIAMETER OF 0.55 TO 2.5 MICRONS AND A BULK DENSITY OF 0.65 TO 1.5 GRAMS PER CC. WHICH COMPRISES TREATING GASEOUS URANIUM HEXAFLUOIDE WITH STEAM AT A 